Hose and Connector Installation Guide: 1 Edition Created: October 2012

Hose and Connector Installation Guide 1
Hose and Connector Installation

Guide
1st Edition
Created: October 2012
Installation Assembly Criteria –

Introduction
While the success of a hydraulic fluid conveyance system

weighs heavily on its design, the assembly of the fluid lines
is just as important to the longevity and success of the
system.
Fluid Lines Designers are provided with various design

analysis tools such as the Fluid Lines Design Software (FLD)
to design a successful lines system. But unless the Lines
Assembler effectively executes routing this design, the
efforts put into designing the intelligent system are wasted,
resulting in leaks, warranty claims, and customer
dissatisfaction.
Table of Contents
Hose and Assembly Identification...................................................... 4
Cat Hose Identification ................................................................ 4
Hose Assembly Identification ...................................................... 5
Types of Couplings ..................................................................... 5
Installation Process ........................................................................... 8
Contamination Controls............................................................... 8
Step-by-Step Installation Process ............................................... 9
Four-Bolt Flanges...................................................................... 13
Hose Twist ...................................................................................... 15
Assembly for a Twist-free Installation ........................................ 16
Consequential Failure Story Board............................................ 16
Path of Hose ................................................................................... 18
Assembly for optimal Hose Path Installation.............................. 19
Abrasion and Contact...................................................................... 23
Types of Abrasion ..................................................................... 24
How to Avoid Abrasion .............................................................. 26
Clips and Clamps ............................................................................ 29
Types of Clamps ....................................................................... 30
Guidelines for Correct Clamping ............................................... 31
Routing Taped Hose Assemblies .............................................. 33
Seals and Lubricant......................................................................... 35

Hose and Assembly Identification
Cat Hose Identification
Each Cat hose is identified with a layline that contains
information specific to that hose including Manufacturer,
product name, ID symbol, dash size, inside diameter,
industry standard, working pressure, Cat 1E Spec, and
MHSA Code. Below is an image illustrating this (Refer to
1E1748 for more information):
On Cat hose the layline is color coded to indicate the hose

type. A few examples of the layline color code are shown in
the table below. A complete list can be seen in layline
specification, 1E1748.
Hose Type 1E Spec Layline Color
XT-3ES 1E0736 Yellow
XT-5ES 1E1036 Red
XT-6ES 1E2836 White
716 1E0716 Blue
294 1E0294 Plum
844 1E0844 Orange
In addition to a layline, each Cat produced hose is printed

with a date code. The date code is ink-jet printed on the
hose and contains the date and location of manufacture for
traceability purposes.
Hose Assembly Identification

Each Cat hose assembly is identified by either a poly or
aluminium tag. Each poly tag contains the hose assembly
part number and a date code for traceability. There is also a
quick response (QR) code that can be scanned to obtain all
necessary assembly and part number information. The
aluminium tags have the hose assembly part number
stamped onto it. An example of each tag is shown below:
Types of Couplings
(1) Band Clamped Bulk Hose: A band clamped joint
should only be used with textile reinforced hose and
is most commonly used for coolant, fuel, air and
hydraulic return lines. Further information can be
found in the Caterpillar Hose/Clamp Joint Design
Guide located on the Redi Search Engine database
or SAE J1508.
From Left to Right: Worm Gear Hose Clamp, Belleville washer, T-bolt spring, and
wave liner hose clamps.
(2) Permanent Crimped Hose Assembly: The

permanent coupling (1E2115) consists of a head,
stem, and shell, shown below.
a. Threaded Coupling
b. Snap to Connect Coupling
c. Flange Coupling.
i. Code 61: Pressure rating of 3,000-5,000 PS
depending on size and angle of the coupling.
ii. Code 62: Pressure rating of 3,000-6,000 PSI
depending on size and angle of the coupling.
ORFS Split Flange

(O Ring Face Seal) (Code 61)
Swivel
Stem Nut Shell
Shell Stem Head

Head
(3) Reusable Hose Assembly

a. Collet-Type Coupling: The collet-type coupling
(1E2189) is used on high pressure XT hose
assemblies. This type of coupling requires special
equipment to assemble and disassemble the
coupling on the hose assembly.
b. Screw-Type Coupling: The screw-type coupling
(1E2436) is used on low pressure applications
such as fuel lines. This type of coupling can be
assembled with hand tools alone.
1. Reusable Hose Assembly
XT Reusable Coupling Assembly Sequence

Refer to NEHS0746-02 for additional information on the
tooling and assembly sequence for XT Reusable Couplings.
Resources that exist within Cat for coupling identification are

the Coupling Identification Wall Chart (PEWP4128) and the
Caterpillar Coupling Identification Guide (PECP2007).
Hose Installation Assembly Criteria –

Installation Process
Key Point
Contamination Controls
The importance of contamination controls cannot be
stressed enough when it comes to hydraulic fluid lines. An
entire fluid system can be compromised by pre-installation
contamination. Do NOT remove the contamination caps or
plugs from the hose assembly until just before installing the
assembly. This will insure the best case scenario for fluid
lines to be protected from contaminants.
Also note:
Floors should not be used as
storage surfaces for hose
assemblies.
Dedicated racks, metal skids,
pallets or tubs must be used
and protected with lids or
protective coverings.
Hoses should be stored on
racks where the ends are
covered and do not touch the
ground.
Step-by-Step Installation Process
(1) Remove contamination controls from hose ends and

examine the hose assembly prior to machine
installation for the following (SAE J1273):
a. Verify the hose part number, hose length, and
routing for compliance with the original
design/drawing or with the provided schematic.
b. Assemblies for nonconformities such as faulty or
incomplete crimp, abrasion, or cut(s) on the hose.
c. Fitting sealing surfaces for burrs, nicks, or other
damage.
d. *Note: Handle the hose with care during
installation. Kinking or bending the hose beyond
the minimum bend radius can reduce hose life.
e. *Note: When replacing hose assemblies in existing
systems, verify that the replacement is of equal
specification to the original assembly.
(2) Assemble the first coupling onto its designated port

adapter. Do NOT tighten the coupling to torque
specification yet, finger tight will suffice temporarily.
a. When assembling a hose with an angled coupling
and a straight coupling, ALWAYS assemble the
end with the angled coupling first. This will allow
for easier installation of the second coupling and
overall hose assembly.
b. On hose assemblies with two straight couplings,
locate the end with the label in the most visible
location for later service.
(3) Route the hose assembly to its second port

connection and assemble the coupling onto the
adapter. Refer to the outlined sections of this
document, most notably “Path of Hose,” to ensure
correct and optimal routing (i.e. Hose Twisting,
Abrasion, Correct Clamping, etc).
(4) Once both hose ends are connected and the hose
routing is finalized, tighten each coupling to its
respective torque specification. Mark each coupling
to signify that it has been tightened to torque spec.
Process is as follows (3 steps):
1. Rotate the coupling to the proper angle for the
hose routing and hand tighten. Mark the
connection with a marker.
Mark a continuous line across the joint.
Mark only the connection that is being
torqued.
Mark ONLY after hand tightening.
*Note that an adapter, NOT hose coupling is being pictured.

The process is the same for both.
2. Tighten fitting to specified torque using only

certified torque wrenches.
a. The use of a back-up wrench is required when

possible. One is used for the tightening of the
coupling nut onto the adapter while the second
wrench is used to keep the crimp shell from
rotating and this twisting the hose. A hose twist
can result from not using a back-up wrench.
b. When tightening, make the best effort to keep the
wrench at a 90° angle to the coupling for the most
consistent and accurate torque application. *Refer
to Caterpillar specification 1E0279 for further
and more detailed instructions.
Fig 1. Torque applied at 90º, 166 Nm achieved.

Fig 2. Torque applied at approx. 30º, 132 Nm achieved.

Notice that incorrect application of the wrench results in
34Nm reduction in assembly torque. This could result in
loosening of the joint and leakage during service as well
as more energy required by the assembler to achieve the
torque spec.
3. Inspect to confirm that the lines between the
two mating hydraulic components are no longer
aligned.
Four-Bolt Flanges
1. Position the flanges so that the bottom surface of the

flange is parallel to the port.
2. Evenly install bolts hand-tight, keeping the gap between
flanges at a minimum. The maximum gap permitted
after final tightening is 4 mm for the summed total of
both sides. For example, a flange could have 2 mm on
both sides, or zero on one side while having 4 mm on
the other.
3. If the bolt torque is not specified on the drawing, tighten
bolts with 1E0279A or 1E0279B.
4. Use one of the following torque methods from the
illustration on the next page:

Hose Twist
Key Point
Since hose is flexible it is possible to twist it along its own
axis, either during installation or during its operational
movement. Avoiding twist during installation depends largely
upon good assembly practice by the mechanic.
It is also important to understand the hose movement during

machine operation to be able to predict and eliminate
potential twist in the hose due to movement. Twisting a
hose can cause a major reduction in hose life. Twisting a
high-pressure hose only 5° can reduce service life by 70%,
and 7° of twist can reduce service life up to 90%.
Correct Incorrect
Assembly for a Twist-free Installation
(1) Assemble angled couplings first. This will allow for

easier installation of the second coupling and overall
hose assembly.
(2) Use two wrenches when tightening the hose ends,
one on the swivel nut and one on the back-up hex of
the coupling to avoid twisting the hose while
tightening.
(3) Make sure the sealing face of the coupling meets flat
with the sealing surface of the adapter to ensure a
leak-free and straight connection between the ports.
(4) Ensure the hose is untwisted and routed correctly in
a relaxed position before tightening to torque
specification.
Consequential Failure Story Board

Because of the flexible nature of hose it is tempting to allow
it to twist during installation or even do so deliberately to
force the hose away from an obstruction. It is also easy to
forget that when a hose moves in more than one plane a
resultant twist occurs.
Avoid the following practices/habits that lead to a twisted

hose assembly:
(1) Pulling or stretching the hose to reach a connection.
If a hose does not comfortably or naturally reach its
designed port, first check to make sure you have the
correct port designated and then check the hose
path using the guidelines outlined in the “Path of
Hose” section.
(2) Using only one wrench to torque the hose couplings
onto the adapters.
(3) Route the hose against its natural curvature.
The consequences of Hose Twist are:

1. Decrease in hose life
2. Flow restriction due to collapsed hose from twist
3. Unwanted hose movement

Path of Hose
Key Point
The ‘natural curvature’ of the hose should follow the installed
hose shape, if possible. On hose with straight couplings this
can be achieved with careful assembly, but this can be more
difficult with angled couplings. When assembling a hose with
angled couplings, always assemble the hose end with the
angled coupling first. This will allow for easier installation of
the second coupling and overall hose assembly.
Natural Curvature
The term ‘natural curvature’ refers to the tendency of a hose
to curve with no external force applied. Hose built on a
flexible mandrel is cured while coiled on a reel and will take
the curvature of the reel. Hose will also take the shape of
the reels used for packaging if left on the reel for any period
of time. This effect usually has minimal impact on service
life but it can have a significant effect on the installation of
larger, stiffer hoses.
Assembly for optimal Hose Path Installation

Below is a list of guidelines for hose assembly on machines.
While it is initially the designer’s responsibility to ensure the
route of each hose is “clean” and effective, the assembler is
just as important to ensure the hoses are routed well (SAE
J1273).
(1) Hoses should run parallel to each other and avoid

crossing.
(2) Hoses should bend only in one plane. Even in a

static installation contraction due to the
pressurisation of the hose will induce a torsional
twisintg load in the hose.
(3) Prevent the hose from contacting and rubbing on

sharp edges, surfaces, electrical cables and
harnesses, and hot or moving objects.
(4) Large hose loops should be aligned with the natural

curvature of the hose. This will ensure the path of a
moving hose loop remains in the intended plane of
motion throughout the full range of movement and
avoids kicking out to the side.
(5) Do not exceed the minimum bend radius of the hose

being installed. As the hose exits the coupling the
hose should remain straight out of the coupling for at
least one hose diameter before bending. Hoses bent
immediately at the coupling will have a reduced life.
L=one hose diameter in the image below.
(6) Hoses should not be routed in such a way to be

easily used as a step or grab handle.
(7) Be sure to not allow fluid to flow or drip on critical or
hot components if disconnecting a hose for
replacement or service.
(8) If a hose is too short or too tight due to poor routing,
a contraction during pressurization can impose
excessive stress on the hose at the coupling and
induce failure.
Incorrect
Correct
Because of the flexible nature of hose it is tempting to route

hoses in multiple directions while disregarding the designed
route. These photos are visual examples of what can occur
due to the assembly of a poor hose path.
Figure 1: Hose too short. Figure 2: Hose bent at coupling.
Figure 3: Hose exceeds bend radius (yellow hose).
The consequences of poor routing are:

1. Decrease in hose life
2. Flow restriction due to exceeded bend radius
3. Abrasion
4. Hose failure

Abrasion and Contact
Key Point
Be Aware of Interference at:

The hose – Although the resilient rubber surface might
appear to withstand impact, the damage to the wire
reinforcement below can significantly weaken the hose
and reduce its life.
The coupling – Bending and distortion of the couplings

can effect:
• Life of the hose assembly
• The performance due to restriction in the flow area
• The sealing performance of the joint
• Assembly and service
Types of Abrasion
(1) Sharp Edge/Corner
Abrasion: Heavy
consideration and
primarily avoidance
should be given to
hose clearance due to
assembly and
operational conditions.
Can the sharp edge
be smoothed off,
edges bent over, round bar welded to contact point,
a clamp be added, or a hose sleeve/guard installed.
(2) Hose to Hose

Abrasion: Consider
the relative orientation
of the 2 hoses –
generally parallel
contact will be less
damaging than hoses
crossing at 45 to 90
degrees. Hoses in
close proximity may
contact in certain operational modes, all should be
considered and checked.
(3) Flat Surface Contact: No surface is truly smooth. In

a working environment abrasive materials can get
caught in-between the hose and the surface. The
hardness of a contacted surface relative to the hose
cover is also a consideration when assessing the risk
of wear to both. This is a minor risk.
(4) Moving Part

Contact:
Consideration should
be given to the
clearance due to
assembly and
operational
conditions. 50 mm
clearance is
recommended.
(5) Small Radius

Corner: Like sharp
edge abrasion, small
radius corners can
wear the hose cover
down and cause
abrasion leading to
hose failure and/or
decreased hose life.
Thermal Threats
All of the heat sources below should be considered for
suitability of the hose selected, risk of contact, and potential
for oil spray to contact the heat source in the event of a hose
or joint failure. Ensure at least 3” of
clearance between hose and heat
source.
- Extreme ambient temperatures
- Point sources of radiant heat
such as exhausts and turbos
- Flame
Electrical Threats
All hoses having steel reinforcement have the potential to
carry electric current. If the hose is in contact with an
electrical harness or battery cable
and the covers of both wear
through, the hose will carry the
current to ground.
How to Avoid Abrasion

In order to avoid abrasion/wear issues the strategy should
be to:
1. Avoid Contact
Use clamping and restraint
techniques if required.
Then, if necessary
2. Modify Surfaces
Ensure hose and contacted surface are suitably
abrasion resistant (i.e. Tough Guard hose). Ensure
abrasion resistance of installation is suitably
validated.
Then, if necessary
3. Add guarding solutions

Add the necessary guarding to hose
and/or contacted surface.
Supporting Information and Training Opportunities

Design Guides
Caterpillar Safety Design Guide
Hose Rub Reference Guide – HCMD Hydraulics Team,
Decatur
Caterpillar Standards
J12.1
SAE Standards
SAE J517
Contact with hose has

worn through electrical
harness.
Hose cover is worn to the

reinforcement from 45º
contact with another hose.
Hose cover is cut by edge

of clip after 180 hours. The
clip was too loose and
reciprocating motion wore
plastic from clip. The
removal of the plastic
exposed a sharp steel
edge which cut cover.
Despite edge protection the

hose cover has worn
through to the
reinforcement on this rig
test after 104 K cycles.

Clips and Clamps
Key Point
The type and positioning of hose retention or clamping
hardware plays an important part in controlling the path of
hose. This will apply to nominally static lines as well as lines
designed to move in conjunction with other machine
functions. Awareness and use of the natural curvature of
the hose can help reduce the amount of clamping required.
In reality, no line is truly static and although the hose may
not be designed for movement it will still experience dynamic
shock and vibration loadings from the machine as well as
internally induced loadings from pressurization.
In both static and dynamic applications, the function of the
clamping mechanism is to:
Prevent the hose from contacting and rubbing on sharp
edges, surfaces, electrical cables and harnesses, and
hot or moving objects.
Position the hose at the correct connection location for
another fluid line or component.
*Safety Warning: Use caution when reaching around
certain clips or clamps or while installing them. Some contain
sharp edges that can easily cause a deep laceration.
Types of Clamps
*Note: Also, always make sure you are using the correct
torque or tightening tool for the given clips/clamp. Using the
incorrect tooling can compromise the effectiveness of the
clip/clamp and decrease the life of the hose.
(1) P-Clips
(2) 2-Piece Clips
(3) Vibration Dampening

(4) Saddle Clips
(5) Tie Mounts & Straps
Guidelines for Correct Clamping
Make sure the clamp being

used is sized correctly and
not too large or too tight for
the hose. A loose clamp will
allow too much room for the
hose to move and result in
abrasion.
Do not clamp high and low

pressure lines together as
they will flex differently.
Also, do not bundle a group
of hoses together with a tie
wrap. Hoses will still be able
to move around within the
bundle and create a non-
parallel routing, which results
in an abrasion risk.
Tie wraps should only be

used for the retention of light,
low pressure hose. Tie
wraps will not prevent
relative movement if used to
strap high pressure hoses
together and will result in
hose wear and tie wrap
failure.
Do NOT route a hose bend
too tight through a clamp or
clip. Hose should pass
through the clamp with at
least 1xOD of straight length
on either side.
Routing Taped Hose Assemblies
When routing taped assemblies, ideally, hose should be

clamped on the tape marks. However, with all hose
assemblies and taping there are tolerances. Hose assembly
tolerances depend on the hose assembly length. The
tolerances for hose assemblies are as follows (from J12.1):
Length (mm) Tolerance

(mm)
< 300 ±3
300 - 450 ±5
450 - 900 ±7
> 900 ± 1%
When hose assemblies differ from the nominal length there

may be times that, although the hose is clamped on the tape
marks, interference with other hoses or components occur.
In situations where fouling occurs it is recommended that the
clamping location be moved off the tape marks, as
necessary, to prevent the interference. Since each machine
will be different there will be some level of personal judgment
required in each routing.
An example of hose assembly tolerance affecting routing is

shown below. The images below show the changes in hose
assembly length that can occur when a hose assembly is
built at nominal length called out on the print, image #1,
versus the top of the tolerances, image #2. The images are
slightly exaggerated to show potential issues.
Image #1: Hose assembly built at nominal length called out on print.
Image #2: Hose assembly built at the top of tolerances called out on print.
When installing a hose assembly at the top of tolerance, like

image #2, all the excess hose will be forced between the last
tape mark and the coupling, as seen in image #3. To
alleviate the issues created by the excess hose the clamps
should be moved off the tape marks and the hose distributed
as necessary to eliminate issues, as seen in image #4.
Image #3: Hose assembly built at the top of tolerances and clamped on tape marks.
Image #4: Hose assembly built at the top of tolerances and not clamped on tape marks,
the excess hose is spread over the length of the routing.
Forcing all the excess hose between the last tape mark and
the coupling can cause routing issues like rubs between
hoses, rubs between hose and machine components, and
hose undesirably bending at coupling. Moving clamps off
tape marks and spreading the excess hose over the length
of the assembly helps to reduce the issues caused when all
the excess hose is forced into one section of the assembly.
Each installation will be different and discretion will have to
be used when moving clamps off tape marks. When
installing hose assemblies at the top of tolerance on some
machines it will be best to spread the excess hose over the
length of the assembly, while on other machines it will be
best to move the excess hose between two different clamps
to prevent hose rubs or fouling.

Seals and Lubricant
Key Points
(1) Retention compounds and lubricants shall not be used
on STOR/ORFS. (MJ1000-68)
Applications where a retention compound is approved and
shall be used can be seen in Figures 1-2, “D”/Rectangular
O-ring applications in ends of hose couplings. (1E4247)
(2) O-rings may be installed into a fitting/adapter without

the use of a tool. However, installing a seal without the use
of a tool places the seal at extreme risk of damage to the o-
ring caused by the threads, and of o-ring spiraling.
Therefore, it is recommended that appropriate tooling be
used for the installation of O-rings. Refer to MJ1000-68 for
further information on tooling selection and application.

Hose and Connector Installation Guide: 1 Edition Created: October 2012

Uploaded by

Copyright:

Available Formats

Hose and Connector Installation Guide: 1 Edition Created: October 2012

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hose and Connector Installation Guide: 1 Edition Created: October 2012

Uploaded by

Copyright:

Available Formats

Hose and Connector Installation Guide 1

Hose and Connector Installation

Installation Assembly Criteria –

While the success of a hydraulic fluid conveyance system

Fluid Lines Designers are provided with various design

Installation Assembly Criteria –

On Cat hose the layline is color coded to indicate the hose

In addition to a layline, each Cat produced hose is printed

Hose Assembly Identification

(2) Permanent Crimped Hose Assembly: The

ORFS Split Flange

Shell Stem Head

(3) Reusable Hose Assembly

1. Reusable Hose Assembly

XT Reusable Coupling Assembly Sequence

Resources that exist within Cat for coupling identification are

Hose Installation Assembly Criteria –

Step-by-Step Installation Process

(1) Remove contamination controls from hose ends and

(2) Assemble the first coupling onto its designated port

(3) Route the hose assembly to its second port

*Note that an adapter, NOT hose coupling is being pictured.

2. Tighten fitting to specified torque using only

a. The use of a back-up wrench is required when

Fig 1. Torque applied at 90º, 166 Nm achieved.

Fig 2. Torque applied at approx. 30º, 132 Nm achieved.

1. Position the flanges so that the bottom surface of the

Hose Installation Assembly Criteria –

It is also important to understand the hose movement during

Assembly for a Twist-free Installation

(1) Assemble angled couplings first. This will allow for

Consequential Failure Story Board

Avoid the following practices/habits that lead to a twisted

The consequences of Hose Twist are:

Hose Installation Assembly Criteria –

Assembly for optimal Hose Path Installation

(1) Hoses should run parallel to each other and avoid

(2) Hoses should bend only in one plane. Even in a

(3) Prevent the hose from contacting and rubbing on

(4) Large hose loops should be aligned with the natural

(5) Do not exceed the minimum bend radius of the hose

(6) Hoses should not be routed in such a way to be

Consequential Failure Story Board

Because of the flexible nature of hose it is tempting to route

Figure 1: Hose too short. Figure 2: Hose bent at coupling.

Figure 3: Hose exceeds bend radius (yellow hose).

The consequences of poor routing are:

Hose Installation Assembly Criteria –

Be Aware of Interference at:

The coupling – Bending and distortion of the couplings

(2) Hose to Hose

(3) Flat Surface Contact: No surface is truly smooth. In

(4) Moving Part

(5) Small Radius

How to Avoid Abrasion

3. Add guarding solutions

Supporting Information and Training Opportunities

Consequential Failure Story Board

Contact with hose has